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T-SB-0138-10 May 28, 2010 Transmission Fluid or Gear Oil Seepage from Transfer Case Vent (AWD) Service Category Drivetrain Section Transfer/4wd/Awd Market USA Applicability YEAR(S) MODEL(S) ADDITIONAL INFORMATION 2004 – 2009 Highlander Drive Type(s): 4WD Engine(s): 3MZ, 2GR, 2AZ Transmission(s): 4AT, 5AT VDS(s): EP21A, ES41A, ES42A, ES43A, HD21A, HP21A WMI(s): JTE 2001 – 2005 RAV4 Drive Type(s): 4WD Engine(s): 2AZ, 1AZ Transmission(s): 4AT VDS(s): HD20V, HH20V WMI(s): JTE 2004 – 2010 Sienna Drive Type(s): 4WD Engine(s): 3MZ, 2GR Transmission(s): 5AT VDS(s): BA22C, BA23C, BK22C, BK23C, DK4CC, JK4CC WMI(s): 5TD TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. TC008-07. Applicability has been updated to include 2007 – 2009 Highlander, 2001 – 2005 RAV4, and 2007 – 2010 Sienna vehicles. TSB No. TC008-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction Some 2004 – 2009 model year Highlander, 2001 – 2005 model year RAV4, and 2004 – 2010 model year Sienna AWD (4WD) vehicles may display a transmission fluid or gear oil seepage from a vent on the right side of the transfer case. The seepage is from the transfer RH (right-hand) bearing retainer No. 2 oil seal. Production improvements have been implemented to prevent this condition from occurring. Follow the repair procedure in this bulletin to replace the RH bearing retainer No. 2 oil seal assembly. © 2010 Toyota Motor Sales, USA Page 1 of 23

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Page 1: Case Vent (AWD) Transmission Fluid or Gear Oil Seepage from Transfer - toyota… ·  · 2017-05-29Transmission Fluid or Gear Oil Seepage from Transfer Case Vent ... Engine(s): 3MZ,

T-SB-0138-10 May 28, 2010

Transmission Fluid or Gear Oil Seepage from TransferCase Vent (AWD)ServiceCategory Drivetrain

Section Transfer/4wd/Awd Market USA

Applicability

YEAR(S) MODEL(S) ADDITIONAL INFORMATION

2004 – 2009 Highlander Drive Type(s): 4WDEngine(s): 3MZ, 2GR, 2AZTransmission(s): 4AT, 5ATVDS(s): EP21A, ES41A, ES42A, ES43A, HD21A,HP21AWMI(s): JTE

2001 – 2005 RAV4 Drive Type(s): 4WDEngine(s): 2AZ, 1AZTransmission(s): 4ATVDS(s): HD20V, HH20VWMI(s): JTE

2004 – 2010 Sienna Drive Type(s): 4WDEngine(s): 3MZ, 2GRTransmission(s): 5ATVDS(s): BA22C, BA23C, BK22C, BK23C, DK4CC,JK4CCWMI(s): 5TD

TSB SUPERSESSION NOTICE

The information contained in this TSB supersedes TSB No. TC008-07.

• Applicability has been updated to include 2007 – 2009 Highlander, 2001 – 2005 RAV4, and2007 – 2010 Sienna vehicles.

TSB No. TC008-07 is Obsolete and any printed versions should be discarded. Be sure to review theentire content of this service bulletin before proceeding.

Introduction

Some 2004 – 2009 model year Highlander, 2001 – 2005 model year RAV4, and 2004 – 2010 modelyear Sienna AWD (4WD) vehicles may display a transmission fluid or gear oil seepage from a venton the right side of the transfer case. The seepage is from the transfer RH (right-hand) bearingretainer No. 2 oil seal. Production improvements have been implemented to prevent this conditionfrom occurring. Follow the repair procedure in this bulletin to replace the RH bearing retainer No. 2oil seal assembly.

© 2010 Toyota Motor Sales, USA Page 1 of 23

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T-SB-0138-10 May 28, 2010 Page 2 of 23

Transmission Fluid or Gear Oil Seepage from Transfer Case Vent (AWD)

Production Change Information

This TSB applies to 2001 – 2005 RAV4 and to Highlander and Sienna vehicles produced BEFOREthe Production Change Effective VINs shown below.

MODEL PLANT DRIVETRAIN PRODUCTION CHANGE EFFECTIVE VIN

Highlander TMK1 AWD JTEES4#A#92137597

Sienna TMMI AWD 5TD#K4CC#AS028750

Warranty Information

OP CODE DESCRIPTION MODEL YEAR MODEL TIME OFP T1 T2

RAV4 (M/T) 11.52001–2005

RAV4 (A/T) 13.6

Highlander(4 cylinder) 9.7

Highlander(V6) 10.32004–2006

Sienna 10.2

2007–2009 Highlander(V6) 11.9

TC7004 R & R Transfer RH BearingRetainer No. 2 Oil Seal

2007–2010 Sienna 9.3

90316-37001 65 57

APPLICABLE WARRANTY• This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60

months or 60,000 miles, whichever occurs first, from the vehicle’s in-service date.

• Warranty application is limited to occurrence of the specified condition described in thisbulletin.

Parts Information

PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME QTY

90316-37001 Same Seal, Oil, No. 2 (for Transfer RHBearing Retainer) 1

90301-70002 Same Ring, O 1

90311-34021 Same Seal, Oil, No. 1 (for Transfer RHBearing Retainer) 1

12157-10010 Same Gasket 3

90301-11018 Same Ring, O 1

36141-21010 Same Gasket, Transfer Cover 1

90366-38020 Same Bearing, Tapered Roller 1

© 2010 Toyota Motor Sales, USA

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T-SB-0138-10 May 28, 2010 Page 3 of 23

Transmission Fluid or Gear Oil Seepage from Transfer Case Vent (AWD)

Required Tools & Equipment

REQUIRED MATERIAL CLASSIFICATION QUANTITY

Transfer Case Oil Hypoid Gear Oil SAE 90 (GL-5) 0.95 U.S. qts (0.9 liters)

ATF Type T-IVTransmission Fluid

ATF WS3.8 U.S. qts (3.6 liters)

FIPG Sealant: Three Bond 1281,or equivalent – As needed

MP Grease – As needed

SPECIAL SERVICE TOOLS (SST’S) PART NUMBER QTY

Oil Seal Puller (or equivalent) 09308-00010 1

Transmission Housing Remover* 09520-10021 1

Crankshaft Front Oil Seal Replacer* 09223-46011-01 1

RH Bearing Retainer Installer* 09387-00090 1

Output Shaft Nut Wrench (or equivalent) 09326-20011 1

Bearing Remover (or equivalent) 09950-00020 1

Differential Drive Pinion Holding Tool 28* 09556-16030-01 1

Replacer Set #1*(Replacer 36)(Replacer 54)(Replacer 62)(Adapter)

09950-60010-01(09951-00360-01)(09951-00540-01)(09951-00620-01)(09952-06010-01)

1

Handle Set*(Handle Assembly 150 – 6.25 inch)

09950-70010-01(09951-07150-01) 1

Plastic Pry Tool Set* 00002-06000-01 1

* Essential SST.

NOTEAdditional SSTs may be ordered by calling 1-800-933-8335.

© 2010 Toyota Motor Sales, USA

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T-SB-0138-10 May 28, 2010 Page 4 of 23

Transmission Fluid or Gear Oil Seepage from Transfer Case Vent (AWD)

ComponentsFigure 1.

1

2

3

4

5

6

7

89

10

11 12

13

14

15

16

17

18

x7

28 (286, 21)

378 (3855, 279)

49 (500, 36)

49 (500, 36)

49 (500, 36)

1 RH Bearing Retainer Sub-assembly

2 RH Bearing Retainer O-ring

3 RH Bearing Retainer Oil Seal No. 1

4 O-ring

5 Side Gear Shaft Holder Bearing

6 Snap Ring

7 RH Bearing Retainer Oil Seal No. 2

8 Ring Gear Mounting Case Washer No. 2

9 Center Differential Case Tapered Roller Bearing RH(Outer Race)

10 No. 2 Plug

11 Gasket No. 2

12 Gasket No. 1

13 No. 1 Plug

14 Drain Plug

15 Drain Gasket

16 Lock Nut

17 Specified Torque

18 Non-reusable Part

© 2010 Toyota Motor Sales, USA

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T-SB-0138-10 May 28, 2010 Page 5 of 23

Transmission Fluid or Gear Oil Seepage from Transfer Case Vent (AWD)

Repair Procedure: Removal

1. Confirm source of gear oil/transmission fluidseepage is from vent on RH bearing retainer.

Figure 2..

1

1 Location of Seepage in RH Bearing Retainer(Vent)

2. Remove the engine assembly with transaxle.

Refer to the Technical Information System (TIS), applicable model and model year RepairManual:

• 2004 Highlander:Engine/Hybrid System – Engine Mechanical – “2AZ-FE / 3MZ-FE: Partial Engine Assy:Replacement”

• 2005 Highlander:Engine/Hybrid System – Engine Mechanical – “2AZ-FE / 3MZ-FE: Partial Engine Assy:Replacement”

• 2006 Highlander:Engine/Hybrid System – Engine Mechanical – “2AZ-FE / 3MZ-FE Engine Mechanical:Engine Assembly: Removal”

• 2007 Highlander:Engine/Hybrid System – Engine Mechanical – “2AZ-FE / 3MZ-FE Engine Mechanical:Engine Assembly: Removal”

• 2008 / 2009 Highlander:Engine/Hybrid System – Engine Mechanical – “ 2GR-FE Engine Mechanical:Engine Assembly: Removal”

© 2010 Toyota Motor Sales, USA

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T-SB-0138-10 May 28, 2010 Page 6 of 23

Transmission Fluid or Gear Oil Seepage from Transfer Case Vent (AWD)

Repair Procedure: Removal (Continued)

• 2001 / 2002 / 2003 / 2004 / 2005 RAV4:Engine/Hybrid System – Engine Mechanical – “Engine Unit: Removal”

• 2004 / 2005 Sienna:Engine/Hybrid System – Engine Mechanical – “3MZ-FE: Partial Engine Assy: Replacement”

• 2006 Sienna:Engine/Hybrid System – Engine Mechanical – “3MZ-FE Engine Mechanical: EngineAssembly: Removal”

• 2007 / 2008 / 2009 / 2010 Sienna:Engine/Hybrid System – Engine Mechanical – “2GR-FE Engine Mechanical: EngineAssembly: Removal”

3. Remove the automatic transmission w/transfer.

Refer to TIS, applicable model and model year Repair Manual:

• 2004 Highlander:Drivetrain – Automatic Transmission/Transaxle – “Automatic Transaxle Assy(U151E/U151F) / (U241E/U140F): Replacement”

• 2005 Highlander:Drivetrain – Automatic Transmission/Transaxle – “Automatic Transaxle Assy(U151E/U151F) / (U241E/U140F): Replacement”

• 2006 Highlander:Drivetrain – Automatic Transmission/Transaxle – “U140F / U151F Automatic Transaxle:Automatic Transaxle Assembly: Removal”

• 2007 Highlander:Drivetrain – Automatic Transmission/Transaxle – “U140F / U151F Automatic Transaxle:Automatic Transaxle Assembly: Removal”

• 2008 / 2009 Highlander:Drivetrain – Automatic Transmission/Transaxle – “ U151F Automatic Transaxle:Automatic Transaxle Assembly: Removal”

• 2001 / 2002 / 2003 / 2004 / 2005 RAV4:Drivetrain – Automatic Transmission/Transaxle – “Automatic Transaxle Unit (U140F):Removal”

• 2004 / 2005 Sienna:Drivetrain – Automatic Transmission/Transaxle – “Automatic Transaxle Assy (U151E/U151F):Replacement”

• 2006 / 2007 / 2008 / 2009 / 2010 Sienna:Drivetrain – Automatic Transmission/Transaxle – “U151F Automatic Transaxle: AutomaticTransaxle Assembly: Removal”

© 2010 Toyota Motor Sales, USA

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T-SB-0138-10 May 28, 2010 Page 7 of 23

Transmission Fluid or Gear Oil Seepage from Transfer Case Vent (AWD)

Repair Procedure: Removal (Continued)

4. Remove the transfer case No. 1 plug and removethe gasket from the plug.

Figure 3..

1

2

1 No. 1 Plug

2 Drain Plug

5. Remove the transfer drain plug and remove thegasket from the drain plug.

6. Remove the transfer assembly.

A. Remove the 2 bolts and 6 nuts.

B. Using a plastic hammer, drive out the transferassembly from the transaxle assembly.

NOTICE

• Disconnect the transfer assembly fromthe transaxle assembly without tilting.

• When moving the transfer assembly, doNOT hold the assembly by the oil seals.

Figure 4. .

© 2010 Toyota Motor Sales, USA

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T-SB-0138-10 May 28, 2010 Page 8 of 23

Transmission Fluid or Gear Oil Seepage from Transfer Case Vent (AWD)

Repair Procedure: Removal (Continued)

7. Remove the transfer cover gasket from thetransfer assembly.

Figure 5. .

8. Using the SST, remove the transfer RH bearingretainer oil seal.SST P/N 09308-00010

NOTICEBe careful NOT to damage the oil-seal-fittedsurface of the retainer.

Figure 6. .

1

1 SST

© 2010 Toyota Motor Sales, USA

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T-SB-0138-10 May 28, 2010 Page 9 of 23

Transmission Fluid or Gear Oil Seepage from Transfer Case Vent (AWD)

Repair Procedure: Removal (Continued)

9. Remove the transfer RH bearing retainer sub-assembly.

A. Remove the 7 bolts from the RH bearingretainer sub-assembly.

Figure 7.

B. Using the SST, make a clearance between theRH bearing retainer sub-assembly and thetransfer case.SST P/N 09950-00020

Figure 8.

1

1 SST

C. Remove the SST.

© 2010 Toyota Motor Sales, USA

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T-SB-0138-10 May 28, 2010 Page 10 of 23

Transmission Fluid or Gear Oil Seepage from Transfer Case Vent (AWD)

Repair Procedure: Removal (Continued)

D. Using the SST, remove the RH bearing retainersub-assembly from the transfer case.SST P/N 09520-10021

Figure 9.

1

1 SST

10. Remove the two O-rings.

Using a plastic pry tool or equivalent, remove thetwo (2) O-rings from the RH bearing retainer.

NOTICEBe careful NOT to damage the retainer’s groovefor the O-ring.

Figure 10. .

11. Remove the center differential case tapered rollerbearing RH (outer race).

A. Hold the RH bearing retainer in a vise.

B. Using the SST, remove the outer race, washer,and No. 2 oil seal from the RH bearingretainer.SST P/N 09308-00010

NOTICEBe careful NOT to damage the oil-seal-fittedsurface of the retainer.

Figure 11. .

1

1 SST

© 2010 Toyota Motor Sales, USA

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T-SB-0138-10 May 28, 2010 Page 11 of 23

Transmission Fluid or Gear Oil Seepage from Transfer Case Vent (AWD)

Repair Procedure: Installation

1. Install a NEW No. 2 oil seal in the RH bearing retainer.

NOTEThe No. 2 oil seal MUST be positioned so that the seal is aligned over the hole located insidethe RH bearing retainer. Failure to properly align the seal so that it seals on BOTH sides ofthe hole (vent) will cause the transfer case to leak fluid out of the vent assembly on the RHbearing retainer.

Figure 12.

NOTEOnly the outer race of the center differential case tapered roller bearing is to be replaced witha NEW part. Reuse of the center differential case tapered roller bearing should prevent therequirement to re-adjust driven pinion preload.

© 2010 Toyota Motor Sales, USA

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T-SB-0138-10 May 28, 2010 Page 12 of 23

Transmission Fluid or Gear Oil Seepage from Transfer Case Vent (AWD)

Repair Procedure: Installation (Continued)

2. Install the transfer RH bearing retainer oil sealNo. 2.

A. Using the SST and a press, install the oil sealNo. 2 to the RH bearing retainer.SST P/N 09950-60010 (09951-00360,09951-00540, 09952-06010), 09950-70010(09951-07150)

NOTECarefully press-fit so that the oil seal isNOT tilted.

B. Apply a small amount of MP grease No. 2 tothe oil seal lip.

Figure 13. .

12

1 SST

2 1.5 – 2.5 mm (0.059 – 0.098 in.)

3. Install the transfer ring gear mounting case washer No. 2 to the RH bearing retainer.

4. Install the center differential case tapered rollerbearing.

Using the SST and a press, install the outer raceto the RH bearing retainer.SST P/N 09950-60010 (09951-00620), 09950-70010(09951-07150)

Figure 14. .

1

1 SST

© 2010 Toyota Motor Sales, USA

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T-SB-0138-10 May 28, 2010 Page 13 of 23

Transmission Fluid or Gear Oil Seepage from Transfer Case Vent (AWD)

Repair Procedure: Installation (Continued)

5. Install the O-rings.

A. Apply Hypoid gear oil to the two NEW O-rings.

B. Install the two (2) O-rings to the RH bearingretainer.

NOTICEBe careful NOT to twist the O-ring and fit itinto the retainer’s groove properly.

Figure 15. .

6. Install the transfer RH bearing retainer sub-assembly.

A. Place the transfer case with the face where theRH bearing retainer is to be installed facingup, as shown in the illustration.

Figure 16.

B. Center-align the center differential control coupling assembly and the case.

© 2010 Toyota Motor Sales, USA

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T-SB-0138-10 May 28, 2010 Page 14 of 23

Transmission Fluid or Gear Oil Seepage from Transfer Case Vent (AWD)

Repair Procedure: Installation (Continued)

C. Apply MP grease No. 2 thinly to area A asshown in the illustration.

HINTApply MP grease No. 2 to prevent the oilseal lip from rolling back.

Figure 17.

A

1 Area A

D. Insert the SST into the transfer RH bearingretainer sub-assembly.SST P/N 09387-00090

NOTICEInsert the SST straight in order NOT todamage the oil seal.

Figure 18.

1

1 SST

© 2010 Toyota Motor Sales, USA

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T-SB-0138-10 May 28, 2010 Page 15 of 23

Transmission Fluid or Gear Oil Seepage from Transfer Case Vent (AWD)

Repair Procedure: Installation (Continued)

E. With the SST and the transfer RH bearing sub-assembly in close contact, install the transferRH bearing retainer sub-assembly together with the SST into the transfer case.

NOTICE

• Avoid interference between the case and the retainer and between the SST andthe transfer ring gear mounting case.

• Carefully check the retainer’s O-ring for damage and incorrect fitting.

HINT

• If the engagement is tight, tap theSST with a hammer placing a brassbar on the center of the SST.

• If the SST and retainer are NOT inclose contact, the seal for the innerend of the retainer may NOT beproperly aligned when the retainergoes into position. This may resultin the lip of the oil seal being rolledback during installation.

• If the SST and retainer are NOTin close contact, the center ofthe retainer or transfer ring gearmounting case may come out ofposition when the retainer is beinginstalled. This can cause the lip ofthe oil seal to be rolled back.

Figure 19.

1

2

1 SST

2 Brass Bar

F. Make sure that the transfer RH bearing retainer sub-assembly and transfer case contactclosely.

© 2010 Toyota Motor Sales, USA

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T-SB-0138-10 May 28, 2010 Page 16 of 23

Transmission Fluid or Gear Oil Seepage from Transfer Case Vent (AWD)

Repair Procedure: Installation (Continued)

G. Tighten the 7 bolts evenly in the order shownin the illustration.Torque: 28 N*m (286 kgf*cm, 21 ft*lbf)

Figure 20.

25

3

14

7

6

H. Remove the SST. Figure 21.

1

1 SST

© 2010 Toyota Motor Sales, USA

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T-SB-0138-10 May 28, 2010 Page 17 of 23

Transmission Fluid or Gear Oil Seepage from Transfer Case Vent (AWD)

Repair Procedure: Installation (Continued)

7. Inspect total preload.

A. Using the SST and a torque wrench, measurethe initial torque between the driven pinionbearing and the ring gear face.SST P/N 09326-20011Torque:Used Bearing:Driven Pinion Preload +0.15 – 0.30 N*m(+1.6 – 3.1 kgf*cm, +1.3 – 2.7 in*lbf)

HINTUse a torque wrench with a fulcrum lengthof 160 mm (6.30 in.).

NOTEMeasure the torque after rotating the bearingin both clockwise and counterclockwisedirections to make it fit.

Figure 22.

1

1 SST

B. If the preload is too large, replace the bearing spacer with a NEW one.

C. If the preload is too small, repeatedly adjust the preload by tightening the lock nut 5 – 10degrees at a time until the standard value is obtained.

D. If the preload is insufficient even though the tightening torque of the lock nut exceeds themaximum of the standard value, loosen the lock nut and apply gear oil SAE 90 (GL-5) tothe lock nut and the screw thread and base of the driven pinion. Then repeat the precedingoperation. If the tightening torque is smaller than the standard, replace the bearing spacerwith a NEW one and adjust it.SST P/N 09326-20011, 09556-16030Torque: 378 N*m (3855 kgf*cm, 279 ft*lbf)

© 2010 Toyota Motor Sales, USA

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T-SB-0138-10 May 28, 2010 Page 18 of 23

Transmission Fluid or Gear Oil Seepage from Transfer Case Vent (AWD)

Repair Procedure: Installation (Continued)

8. Install the transfer RH bearing retainer oil seal.

A. Using the SST, drive the oil seal into the RHbearing retainer to the position shown in theillustration.SST P/N 09223-46011

NOTICEDrive in the oil seal carefully so that it willNOT be tilted.

B. Apply MP grease to the oil seal lip.

Figure 23. .

1

2

1 SST

2 0.7 – 1.3 mm (0.028 – 0.051 in.)

9. Install a NEW transfer cover gasket to the case. Figure 24. .

© 2010 Toyota Motor Sales, USA

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Transmission Fluid or Gear Oil Seepage from Transfer Case Vent (AWD)

Repair Procedure: Installation (Continued)

10. Install the transfer assembly.

A. Apply FIPG sealant 1281 to the transaxleassembly and the transfer assembly incontinuous beaded form of 1.2 mm (0.05 in.)diameter as shown in the illustration.FIPG sealant: Three Bond 1281, or equivalent

NOTICE

• Remove any grease from the attachingsurfaces.

• Install the transfer assembly within 10minutes after application of the sealant.

• Sealant stuck on the gasket, case oilseal, and driving plug may cause oilleakage and seizure due to oil shortage.

Figure 25.

1

2

3

1 Driving Plug

2 Sealant

3 Gasket

B. Install the transfer assembly to the transaxleassembly with the 2 bolts and 6 nuts.Torque: 69 N*m (700 kgf*cm, 51 ft*lbf)

NOTICE

• Check that the gasket is installed to thetransfer assembly before instaling it tothe transaxle assembly.

• Install the transfer assembly to thetransaxle assembly without tilting.

• When moving the transfer assembly, doNOT hold by the oil seals.

Figure 26.

© 2010 Toyota Motor Sales, USA

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Transmission Fluid or Gear Oil Seepage from Transfer Case Vent (AWD)

Repair Procedure: Installation (Continued)

11. Install the automatic transmission w/transfer.

Refer to TIS, applicable model and model year Repair Manual:

• 2004 Highlander:Drivetrain – Automatic Transmission/Transaxle – “Automatic Transaxle Assy(U151E/U151F) / (U241E/U140F): Replacement”

• 2005 Highlander:Drivetrain – Automatic Transmission/Transaxle – “Automatic Transaxle Assy(U151E/U151F) / (U241E/U140F): Replacement”

• 2006 Highlander:Drivetrain – Automatic Transmission/Transaxle – “U140F / U151F Automatic Transaxle:Automatic Transaxle Assembly: Installation”

• 2007 Highlander:Drivetrain – Automatic Transmission/Transaxle – “U140F / U151F Automatic Transaxle:Automatic Transaxle Assembly: Installation”

• 2008 / 2009 Highlander:Drivetrain – Automatic Transmission/Transaxle – “U151F Automatic Transaxle:Automatic Transaxle Assembly: Installation”

• 2001 / 2002 / 2003 / 2004 / 2005 RAV4:Drivetrain – Automatic Transmission/Transaxle – “Automatic Transaxle Unit (U140F):Installation”

• 2004 / 2005 Sienna:Drivetrain – Automatic Transmission/Transaxle – “Automatic Transaxle Assy (U151E/U151F):Replacement”

• 2006 / 2007 / 2008 / 2009 / 2010 Sienna:Drivetrain – Automatic Transmission/Transaxle – “U151F Automatic Transaxle: AutomaticTransaxle Assembly: Installation”

12. Install the engine assembly with transaxle.

Refer to TIS, applicable model and model year Repair Manual:

• 2004 Highlander:Engine/Hybrid System – Engine Mechanical – “2AZ-FE / 3MZ-FE: Partial Engine Assy:Replacement”

• 2005 Highlander:Engine/Hybrid System – Engine Mechanical – “2AZ-FE / 3MZ-FE: Partial Engine Assy:Replacement”

• 2006 Highlander:Engine/Hybrid System – Engine Mechanical – “2AZ-FE / 3MZ-FE Engine Mechanical:Engine Assembly: Installation”

© 2010 Toyota Motor Sales, USA

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T-SB-0138-10 May 28, 2010 Page 21 of 23

Transmission Fluid or Gear Oil Seepage from Transfer Case Vent (AWD)

Repair Procedure: Installation (Continued)

• 2007 Highlander:Engine/Hybrid System – Engine Mechanical – “2AZ-FE / 3MZ-FE Engine Mechanical:Engine Assembly: Installation”

• 2008 / 2009 Highlander:Engine/Hybrid System – Engine Mechanical – “ 2GR-FE Engine Mechanical:Engine Assembly: Installation”

• 2001 / 2002 / 2003 / 2004 / 2005 RAV4:Engine/Hybrid System – Engine Mechanical – “Engine Unit: Installation”

• 2004 / 2005 Sienna:Engine/Hybrid System – Engine Mechanical – “Partial Engine Assy: Replacement”

• 2006 Sienna:Engine/Hybrid System – Engine Mechanical – “3MZ-FE Engine Mechanical: EngineAssembly: Installation”

• 2007 / 2008 / 2009 / 2010 Sienna:Engine/Hybrid System – Engine Mechanical – “2GR-FE Engine Mechanical: EngineAssembly: Installation”

13. Install the transfer drain plug with a NEW gasket.Torque: 49 N*m (500 kgf*cm, 36 ft*lbf)

Figure 27. .

1

2

1 No. 1 Plug

2 Drain Plug

© 2010 Toyota Motor Sales, USA

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T-SB-0138-10 May 28, 2010 Page 22 of 23

Transmission Fluid or Gear Oil Seepage from Transfer Case Vent (AWD)

Repair Procedure: Installation (Continued)

14. Install the transfer case No. 1 plug.

A. Add oil up to the level 0 – 5 mm (0 – 0.20 in.) below the lowest end of the plug hole.Oil quantity:0.95 U.S. qts (0.9 L, 0.71 lmp. qts)

NOTEAdd oil slowly.

B. Install the No. 1 plug with a NEW gasket.Torque: 49 N*m (500 kgf*cm, 36 ft*lbf)

15. Inspect and adjust front wheel alignment.

Refer to TIS, applicable model and model year Repair Manual:

• 2004 / 2005 Highlander:Suspension – Alignment/Handling Diagnoses – “Front Wheel Alignment:Adjustment”

• 2006 / 2007 / 2008 / 2009 Highlander:Suspension – Alignment/Handling Diagnoses – “Suspension: Front Wheel Alignment:Adjustment”

• 2001 / 2002 / 2003 / 2004 / 2005 RAV4:Suspension – Alignment/Handling Diagnoses – “Front Wheel Alignment: Inspection”

• 2004 / 2005 Sienna:Suspension – Alignment/Handling Diagnoses – “Front Wheel Alignment: Adjustment”

• 2006 / 2007 / 2008 / 2009 / 2010 Sienna:Suspension – Alignment/Handling Diagnoses – “Suspension: Front Wheel Alignment:Adjustment”

16. Check the ABS speed sensor signal (ABS with EBD & BA & TRAC & VSC system).

Refer to TIS, applicable model and model year Repair Manual:

• 2004 / 2005 Highlander:Brake – Brake Control/Dynamic Control System – “ABS With EBD & BA &TRAC & VSC System: Pre-Check”

• 2006 / 2007 / 2008 / 2009 Highlander:Brake – Brake Control/Dynamic Control System – “Brake Control: Vehicle Stability ControlSystem: Test Mode Procedure”

• 2001 / 2002 / 2003 / 2004 / 2005 RAV4:Brake – Brake Control/Dynamic Control System – “Anti-Lock Brake System With ElectronicBrake Force Distribution (EBD): Pre-Check”

© 2010 Toyota Motor Sales, USA

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T-SB-0138-10 May 28, 2010 Page 23 of 23

Transmission Fluid or Gear Oil Seepage from Transfer Case Vent (AWD)

Repair Procedure: Installation (Continued)

• 2004 / 2005 Sienna:Brake – Brake Control/Dynamic Control System – “ABS With EBD & BA & TRAC & VSCSystem: Pre-Check”

• 2006 / 2007 / 2008 / 2009 / 2010 Sienna:Brake – Brake Control/Dynamic Control System – “Brake Control: Anti-lock Brake System:Test Mode Procedure”

17. Re-initialize any affected power systems.

Refer to TIS for the applicable TSB or Repair Manual section.

© 2010 Toyota Motor Sales, USA